Plastic Pallet

ABSTRACT

A plastic pallet and method of construction that permits plastic pallets of numerous different sizes and options to be easily produced from only a very small inventory of parts and without requiring a user to purchase or construct numerous different shapes and sizes of molds in order to produce a wide variety of pallets of various shapes, sizes and options.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of the filing ofU.S. Provisional Patent Application Ser. No. 62/340,649, entitled“Plastic Pallet”, filed on May 24, 2016, and the specification thereofis incorporated herein by reference.

BACKGROUND OF THE INVENTION Field of the Invention (Technical Field)

Embodiments of the present invention relate to plastic pallets and amethod for the manufacture thereof.

Description of Related Art

Although pallets have been in use for a long time, conventional woodenpallets suffer from various issues, including their susceptibility torot, they are attacked by wood-eating pests, the wood can crack and bowwith age and with changes in humidity, and the strength of woodenpallets changes as the wood ages and as decay occurs. While plasticpallets have been known for a while, such pallets are typically formedas a single continuous molded product. As such, to provide pallets ofnumerous dimensions and sizes, numerous molds must be created andsubsequently stored. This makes it expensive to quickly andinexpensively provide customized pallet sizes—particularly forcustomized pallets where small quantities are desired.

Although a few plastic pallets are known that can be formed fromindividual components, such known plastic pallets typically rely on aninterference-fit or other self-securing method of attachment between thevarious components. Therefore, the strength of such connections are onlyas strong as the plastic connectors that are integrally formed therein.In addition, the size of the pallets cannot be adjusted withoutlimitation. This is because the connection between two components canonly occur where an integral connector has already been formed.

There is thus a need for a plastic pallet and method of constructionwhich permits plastic pallets to be formed to any size and which can beaccomplished with only a few basic components; and which further canrely on stronger metal fasteners for the connections between thecomponents instead of weaker and limiting integrally-formed plasticconnectors.

BRIEF SUMMARY OF EMBODIMENTS OF THE PRESENT INVENTION

An embodiment of the present invention relates to a plastic pallethaving a plastic top plate with a textured pattern formed on at leastone side thereof, two or more plastic stringers, at least one bottomboard, the at least one bottom board having a textured pattern surface,and a first plurality of fasteners securing the bottom boards to thestringers. The plastic pallet can also include a second plurality offasteners securing the plastic top plate to the two or more plasticstringers. The stringers can be integrally formed in the plastic topplate. The top plate can include a plurality of corner pieces projectingfrom a top thereof. The plastic pallet can optionally include a firstIBC attached thereto. In one embodiment, the top plate can include avoid formed at a location below an outlet of the first IBC. The bottomboard can optionally include an opening that aligns with an inlet of asecond IBC when the plastic pallet is placed atop the second IBC. Thebottom board can be sized to sit inside of a frame for a second IBC. Thestringers can extend beyond the at least one bottom board by at least1.5 inches on each end. The plastic pallet can also include one or morebarrel retention spaces formed on the top plate, the barrel retentionspaces defined at least partially by one or more corner pieces. Thebarrel retention spaces can be further defined by one or more barrelspacers. The plastic pallet can include four or more barrel retentionspaces formed on the top plate.

In one embodiment, the two or more plastic stringers can include astiffener cutout. The plastic pallet can include at least one stiffenerextending from at least one of the two or more stringers to at least oneother of the two or more stringers. The first plurality of fasteners caninclude metal screws.

An embodiment of the present invention also relates to a plastic pallethaving a plastic top plate with two or more integrally formed stringers,at least one bottom board, and a first plurality of metal screwssecuring the bottom boards to the stringers. The plastic pallet caninclude an IBC attached to a top thereof and the plastic top plate caninclude a void formed at a location below the IBC.

An embodiment of the present invention also relates to a method forforming a plastic pallet including attaching a plastic top plate to twoor more plastic stringers; and attaching at least one bottom board tothe two or more plastic stringers with a plurality of metal fasteners.Optionally, attaching a plastic top plate to two or more plasticstringers can include integrally forming the two or more plasticstringers into the plastic top plate. The method can include forming theplastic top plate from a compression mold and the at least one bottomboard can be at least partially formed from the compression mold. Themethod can include at least partially forming the at least one bottomboard by cutting it to a desired size.

Objects, advantages and novel features, and further scope ofapplicability of the present invention will be set forth in part in thedetailed description to follow, taken in conjunction with theaccompanying drawings, and in part will become apparent to those skilledin the art upon examination of the following, or may be learned bypractice of the invention. The objects and advantages of the inventionmay be realized and attained by means of the instrumentalities andcombinations particularly pointed out in the appended claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The accompanying drawings, which are incorporated into and form a partof the specification, illustrate one or more embodiments of the presentinvention and, together with the description, serve to explain theprinciples of the invention. The drawings are only for the purpose ofillustrating one or more preferred embodiments of the invention and arenot to be construed as limiting the invention. In the drawings:

FIG. 1 is a drawing which illustrates an under-side of a pallet havingbottom boards according to an embodiment of the present invention;

FIG. 2 is a drawing which illustrates an underside of a pallet withoutbottom boards;

FIG. 3 is a drawing which illustrates a pallet having a flat-top plateaccording to an embodiment of the present invention;

FIGS. 4A, 4B, and 4C respectively illustrate top, bottom, and side-viewdrawings of a pallet according to an embodiment of the present inventionhaving four stringers;

FIGS. 5A, 5B, and 5C respectively illustrate top, bottom, and side-viewdrawings of a pallet according to an embodiment of the present inventionhaving three stringers;

FIGS. 6A, 6B, and 6C respectively illustrate top, bottom, and side-viewdrawings of a pallet having a plurality of spaced-apart top platesaccording to an embodiment of the present invention;

FIG. 7 is a drawing which shows one embodiment of how the shaped surfaceof the leg can plug into or otherwise interact with the shaped surfaceof a top plate;

FIG. 8 is a drawing which shows an embodiment of the present inventionwherein a plurality of legs are attached to a top plate;

FIGS. 9A, 9B, and 9C respectively illustrate top, bottom, and side-viewdrawings of a pallet formed by a plurality of legs separating top platefrom a base board;

FIG. 10 is a drawing of a mold for forming top plates according to anembodiment of the present invention;

FIG. 11 is a drawing of a pallet according to an embodiment of thepresent invention wherein a top surface of the top plate has faux boardsformed therein;

FIG. 12A is a perspective view drawing of a stringer with cutouts toaccommodate stiffeners;

FIG. 12B is a side-view drawing of a pallet with the ends of stiffenersexposed;

FIGS. 13A, and 13B respectively illustrate a top and side view of apallet with barrel spacers and corner pieces attached to the top plateto accommodate up to five barrels;

FIG. 13C is a drawing which illustrates a barrel spacer and corner piecefor the embodiment of FIG. 13A;

FIG. 14A illustrates a top and side view of a pallet with barrel spacersand corner pieces attached to the top plate to accommodate up to fourbarrels;

FIG. 14B is a drawing which illustrates barrel spacers and a cornerpiece for the embodiment of FIG. 14A;

FIG. 14C is a drawing which illustrates a top view of a pallet withbarrel spacers and corner pieces having straight sides;

FIGS. 15A and 15B are drawings which illustrate an embodiment of anintermediate bulk container (“IBC”) pallet according to an embodiment ofthe present invention;

FIG. 15C is a drawing which illustrates an IBC pallet stacked atop anIBC according to an embodiment of the present invention;

FIG. 16 is a drawing which illustrates an embodiment of the presentinvention wherein stringers are integrally formed into a top plate;

FIGS. 17A and 17B respectively illustrate top and bottom views of anestable pallet according to an embodiment of the present invention;

FIG. 17C is a drawing which illustrates a side-view of the nestablepallet of FIGS. 17A and 17B; and

FIG. 17D is a drawing which illustrates a plurality of nestable palletsstacked together according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, an embodiment of the present inventionrelates to plastic pallet 10 having top plate 12, attached by fasteners13 to stringers 14. The term “plastic” as used throughout thisapplication is intended to include not only materials that areconventionally referred to as plastic materials, but also any othersynthetic solid material, including not only materials that have aslightly elastic form, but also rigid, non-elastic materials, includingbut not limited to epoxies, glass-filled resins, combinations thereofand the like. In one embodiment, fasteners 13 are also preferably usedto attach bottom boards 16 to stringers 14. In one embodiment, bottomboards 16 can be formed by cutting a piece of top plate material 12 intostrips. Fasteners 13 are preferably metal fasteners and most preferablyscrews. Although carbon-steel screws can be used and will providedesirable results for numerous applications, in one embodiment, thescrews are most preferably galvanized or stainless steel. In oneembodiment, when using metal screws to attach one or more piece ofpallet 10 together, the screw preferably generates heat from thefriction of its installation and thus causes the plastic thatimmediately surrounds it to melt slightly and thus adhere to the screw.This therefore locks the screw in place and reduces the potential forthe screw to gradually back out. In one embodiment, nails can be usedfor one or more of fasteners 13.

In one embodiment, bottom boards 16 can optionally be omitted (see FIG.2). In a further embodiment, stringers 14 can have notches formed inthem such that gaps for forks of a forklift are provided along the sidesof pallet 10 (this configuration is typically referred to as a “4-way”pallet). In one embodiment, bottom boards 16 can comprise a plurality ofboards that are parallel with one another. Alternatively, however, asingle bottom board 16 can be provided. In this embodiment, bottom board16 can be a duplicate of top plate 12, thus covering substantially theentire bottom of pallet 10. In one embodiment, a plurality of bottomboards 16 can be provided and each can be formed by cutting a strip oftop plate material. For example, in one embodiment, a pair of top plates12 can be formed, one of those top plates can be cut into strips andsome or all of those strips can be used as bottom boards 16. In oneembodiment, two stringers 14 can be provided. More preferably, three orfour stringers can optionally be provided (see FIGS. 4B and 5Brespectively). In an alternative embodiment, any number of a pluralityof stringers 14 can be provided. In one embodiment, one or morestringers can be wider at the top and the bottom such that the stringercomprises an I-beam cross-section, thus, stiffening the stringer andreducing lateral deflection while also providing a wider area at the topof the stringer to provide a larger area for its attachment to top plate12.

In one embodiment, top plate 12 can comprise a standard width and length(for example, top plate 12 can optionally be about 48″ wide by about 48″long). In this embodiment, for pallets that are longer than top plate12, more than one top plate can be used. For example, if a user desiresto have a pallet that is six feet long by three feet wide, a first topplate can be cut such that it is four feet by three feet. Then, a secondtop plate can be cut such that it is three feet by two feet. The two topplates can then be butted together to proved a top plate assembly thatis six feet by three feet. Likewise, if a pallet is desired that is fourfeet by twelve feet, three top plates 12, each measuring four feet byfour feet, can be butted together and then stringers 14 can be connectedthereto to form the desired pallet.

In one embodiment, top plate 12 can be cut into strips and spaced apartsuch that there are gaps in top plate 12 once pallet 10 is constructed(See FIG. 6A). In one embodiment, top plate 12 can have a shaped surfaceon one or both major surfaces thereof. For example, as best illustratedin FIGS. 7 and 8, top plate 12 can have a square recesses 22 formed byraised ribs 24. Of course other shapes and designs of shaped surface oftop plate 12 can be used and will provide desirable results. In oneembodiment, for example, one or both sides of top plate 12 can havevarious shapes and/or textured patterns formed therein. The term“textured pattern” as used throughout this application is intended tomean an anti-slip and/or friction and/or friction-inducing patternintentionally formed onto a surface that comprises a height and/or depthof at least 1/16 of an inch, and more preferably comprising a heightand/or depth of at least ⅛ of an inch, and most preferably comprising aheight and/or depth of at least about ¼ of an inch. The term “texturedpattern” thus includes ribbed structures, a waffle pattern, adiamond-shaped pattern, or shaped surface patterns or textures andincludes but is not limited to the grid pattern illustrated in some ofthe drawings. In one embodiment, a company logo or other image can beformed into the top surface of top plate 12. In yet a furtherembodiment, as best illustrated in FIG. 11, the top surface of top plate12 can have faux boards 30 formed therein. Because in one embodiment,bottom boards 16 are formed by cutting a top plate 12 into strips,bottom boards 16 can also thus comprise these same textured patternsformed therein.

By providing a top plate 12 having a smooth first major surface and ashaped second major surface (for example a smooth top and a shapedbottom), a user can apply top plate 12 such that either the smooth sideis up or such that the smooth side is down. This permits furthercustomization of the resulting pallet for a particular good to be movedor shipped thereon. For example, powdered or liquid goods that arestored in a bag will benefit from shipping them on pallets having theshaped surface facing up because the bag can conform to the shapedsurface, thereby helping to lock the bag in place and inhibiting the bagand its contents from sliding about on the pallet. Because someembodiments of the present invention also form bottom boards 16 from thesame material that top plate 12 is formed from, the resulting plasticpallet can further be customized for a particular application byattaching bottom boards with the shaped surface side down or the smoothside down.

In one embodiment, as best illustrated in FIG. 7-9C, legs 18 can beprovided to be used in place of stringers 14. In this embodiment, leg 18most preferably comprises shaped surface 20 on its upper and/or lowersurfaces. In this embodiment, shaped surface 20 most preferablycomprises a shape and dimensions which permit shaped surface 20 toengage recesses 22 and/or protrusions 24 of top plate 12. Fastener 13,which is most preferably a metal screw, is used to secure leg 18 to topplate 12. The engageable arrangement between 20, 22, and 24, permits astronger connection between legs 18 and top plate 12. For example, whenused in its intended operating position, lateral forces experienced byleg 18 are received and distributed to ribs 24 of top plate 12, whereaswithout the engageable surfaces, metal fastener 13 would have to receiveand transfer all of the lateral force. In one embodiment, legs 18 canhave one or more protrusions as part of its shaped surface 20. In apreferred embodiment, legs 18 can have four protrusions as part of itsshaped surface 20. In one embodiment, both end surfaces of legs 18comprise a shaped surface.

Although pallet 10 can be formed simply by attaching legs 18 to topplate 12 with fasteners 13, such as that illustrated in FIG. 8, in oneembodiment, bottom boards 16 are also preferably used to increase thestrength and rigidity of the resulting pallet 10. See for example, FIGS.9A-9C. As best illustrated in FIG. 9B, in one embodiment, bottom boards16 can be formed simply by cutting large voids in a piece of materialthat matches top plate 12 (in the case of FIG. 9B, four largerectangular voids have been cut into bottom board 16).

As best illustrated in FIG. 10, in forming top plate 12, mold 26 ispreferably used. The protrusions on the mold result in recesses 22 (seeFIG. 7). In one embodiment wherein pallets 10 are to be formed withstringers 14, a solid structure, such as a board or other strip ofmaterial, can be secured to mold 26 at the location of where stringers14 are desired to be attached to the resulting top plate 12. Then,plastic material is applied to mold 26 and allowed to harden. When theresulting top plate is removed from the mold, the top plate has a recessformed along the location of where the strip of material was attached.The stringer can then be placed down into that recess and, if the stripof material had a width substantially similar to that of the stringer,the stringer will fight snugly into the recess. This helps to bettersecure stringer 14 to top plate 12, thereby resulting in a more durableplastic pallet. In one embodiment, however, recesses 22 are not formedinto top plate 12. In this embodiment, stringers 14 are simply attachedto top plate 12.

As best illustrated in FIGS. 12A and B, in one embodiment, stringers 14can comprise one or more cut-outs 32 to accommodate stiffeners 34. Inone embodiment, stiffeners 34 are preferably disposed near the edges oftop plate 12 and preferably span the entire width of the pallet. In thisembodiment, stiffeners 34 preferably comprise strips of material. Forexample, in one embodiment, a stiffener can have a width of about twoinches to about six inches, and more preferably about four inches. Inone embodiment, stiffener 34 can comprise a thickness of from about ½ ofan inch to about two inches and most preferably a thickness of fromabout one inch. Other dimensions can be used to accommodate anyparticular application. In one embodiment, as best illustrated in FIG.12B, stiffener 34 can be disposed in a location where one portion of atop plate abuts another portion of a top plate. In one embodiment,stiffener 34 is preferably formed from a plastic material. In oneembodiment, top plate 12 is preferably attached to stiffener 34 via oneor more fasteners 13.

Referring now to FIGS. 13A-13C, in one embodiment, pallet 10 can beconfigured to provide barrel retention spaces 36 to hold barrels byattaching barrel spacers 38 and corner pieces 40 to top plate 12.Optionally, pallet 10 can be configured to hold one or more barrels, andmost preferably four or five barrels in a standing configuration (i.e.with the primary axis of each barrel placed perpendicular to top plate12). FIG. 13A illustrates an embodiment of pallet 10 configured toaccommodate up to five barrels via five barrel retention spaces 36. Inone embodiment, barrel spacers 38 and corner pieces 40 can be attachedto top plate 12 via one or more fasteners. Of course, in one embodiment,barrel spacers 38 and corner pieces 40 can optionally be formed into asingle continuous piece of material such that they are all connectedtogether (for example, by forming the single continuous piece ofmaterial as a molded plate with barrel retention spaces 36 formedtherein). In an alternative embodiment, only barrel spacers 38 or cornerpieces 40 can be provided. In addition, although FIG. 13C illustrates amost preferred shape for each of barrel spacers 38 and corner pieces 40for a pallet 10 configured to accommodate five barrels, different shapescan optionally be used for one or both of barrel spacers 38 and/orcorner pieces 40 and will provide desirable results. For example, thecurves and spacing between them as illustrated on barrel spacer 38 canhave a different radius and/or spacing such that any one or more ofbarrel spaces 36 can have a different diameter from any other of thebarrel spacers. In one embodiment, top plate 12 can have barrel spacers38 and/or corner pieces 40 formed directly its upper surface. Forexample, top plate 12 can have increased thickness where barrel spacers38 and/or corner pieces 40 are desired. This can optionally be done bymolding or milling barrel retention spaces 36 into top plate 12.

FIGS. 14A and B illustrate an embodiment wherein four barrel retentionspaces 36 are provided on pallet 10 via barrel spacers 38 and 42, andcorner pieces 40. In this embodiment central barrel spacer 42 ispreferably disposed at or near a center of top plate 12.

As best illustrated in FIG. 14C, barrel spacers 38, corner pieces 40 andcentral barrel spacer 38, if provided, can comprise one or more straightsides. In this figure barrels 43 are illustrated as being disposed inbarrel retention spaces 36 (not shown because they are covered bybarrels 43). Optionally one or more of barrel spacers 38, corner pieces40, and central barrel spacer 42 can be formed from more than one piece.For example, in one embodiment, central barrel spacer 42 can be formedfrom a plurality of elongated pieces that are arranged to form a squareor another shape as illustrated in FIG. 14C. In one embodiment, fourcorner pieces 40 could optionally be used in place of central barrelspacer 42. Although FIGS. 13A-14C illustrate an embodiment whereincorner pieces 40 can be used in conjunction with barrel spacers 38and/or 42 in order to form barrel retention spaces 36, corner pieces 40can be applied to any other pallet to help prevent its contents(regardless of whether it is barrels or not) from shifting off of thepallet when it is in transit. In addition, one or more strips ofmaterial can be attached with fasteners or formed onto any desiredlocation on the top plate 12 to prevent contents from easily sliding offof the pallet. For example, in one embodiment, four strips of materialcan be attached or formed along the perimeter of top plate 12.

In one embodiment, as best illustrated in FIGS. 15A-C, pallet 10 can beconfigured to accommodate or incorporate an intermediate bulk container(“IBC”) 44 and its accompanying space frame 45. In this embodiment,frame 45 is preferably attached to top plate 12 via a plurality offasteners 13. In this embodiment, pallet 10 is preferably sized suchthat one or more—and most preferably all of stringers 14—are positionedsuch that fasteners 13 that attach frame 45 to top plate 12 will passdown into stringers 14 (see FIG. 15A). In this embodiment, a pair ofstringers 14 are preferably disposed on the sides of pallet 10—of coursewider stringers 14 could also optionally be used on each respective leftand right side of pallet 10 in lieu of a pair of stringers 14. In thisembodiment, top plate 12 preferably comprises cutout 48 beneath outlet50 of IBC, thus providing increased access to outlet 50. Bottom board 16preferably comprises notched corners 46 and most preferably all ofbottom boards 16 (for embodiments where a plurality of bottom boards 16are used) of a pallet are preferably positioned and/or cut such that theoutside perimeter of bottom boards 16 comprise dimensions that aresmaller than the inside perimeter of frame 45. Thus, when a first pallet10 comprising IBC 44 is placed atop a second pallet 10 comprising IBC44, bottom boards 16 preferably rest inside of frame 45 of IBC 44 of thefirst pallet, thus locking the top pallet onto the bottom IBC andpreventing the top pallet from sliding and/or shifting during transport(see FIG. 15C which illustrates bottom boards 16 nestled down withinframe 45 of the lower pallet). In this embodiment, stringers 14preferably extend further than bottom boards 16 so that when stackedatop an IBC, the stringers rest on frame 45 of IBC 44. Thus, the entireweight of the top pallet and its contents are transferred down throughits stringers and onto the frame of the lower IBC. In one embodiment, anopening can be disposed in a bottom board 16 at a location that alignswith a top inlet and fill cap for an IBC. Thus, when a top pallet isstacked atop a lower IBC, the fill cap and inlet that projects above thelower IBC will not be pressed against by the bottom boards of the toppallet.

Referring now to FIG. 16, in one embodiment, stringers 14 can beintegrally formed into top plate 12. As used throughout thisapplication, the term “integrally formed” is intended to include anymanner of forming two items together from a single continuous piece ofmaterial or separate materials without the use of adhesives or fastenersor an interference fit. Thus the term “integrally formed” can includetwo items molded together in a single mold and can include two itemsformed together by milling down a single piece of material. In thisembodiment, stringers 14 and top plate 12 are most preferably all moldedtogether in a single mold, thus forming a single, continuous piece ofmaterial. This embodiment of the integrally-formed stringers 14 can beused in all of the previously described embodiments wherein stringers 14are attached to top plate 12, however, fasteners 13 are of course notneeded to secure stringers 14 to top plate 12 when they are integrallyformed. Thus, the integrally-formed stringers can be used in all ofpallets of FIGS. 1-6 and 11-15C. Thus, one or more bottom boards 16 canbe attached to the integrally formed stringers. In addition, one or moreof the stringers 14 can be made wider or more narrow than one or moreother stringers 14. For example, in one embodiment, the outsidestringers on the left and right of FIG. 16 can be made twice as thick asthe inside stringer if desired for a particular application. As with theembodiment of FIGS. 12A and B, one or more cutouts can be disposed orformed in the integrated stringers such that one or more stiffeners 34can be slid therethrough and then secured to top plate 12, for examplevia one or more fasteners. Alternatively, top plate 12 can optionallycomprise stiffeners 34 integrally formed such that stiffeners 34 extendbetween two or more of stringers 14—particularly at or near the edge oftop plate 12.

Referring now to FIGS. 17A-17D, in one embodiment, pallet 10 compriseselevated nubs 54 which preferably project above the rest of top plate12. Although the height of nubs 54 can be provided to have any desiredheight, in a preferred embodiment, nubs 54 preferably project from about¼ inch to about 1.5 inches above top plate 12, and more preferably fromabout ½ inch to about inch above top plate 12 and most preferably about⅝ inch above top plate 12. Although FIG. 17A illustrates nubs 54 ascomprising a square shape, nubs 54 can comprise any desirable shape forany particular application. Nubs 54 preferably permit cargo, such aslarge bags of bulk products to be placed onto top plate 12 and settlearound nubs 54, thus helping to prevent such cargo from slipping off ofpallet 10 while in transit. As best illustrated by the dashed lines ofFIG. 17A, nubs 54 most preferably align to fall inside of openings 56 onbottom boards 16. As such, when two empty pallets are stacked atop oneanother (see FIG. 17D), nubs 54 of the bottom pallet preferably projectup into openings 56 in the bottom of the top pallet, thus nesting thetwo pallets together and preventing the top pallet from sliding off ofthe bottom pallet when in transit. Openings 56 are also preferablyprovided to permit load-bearing wheels of pallet jacks to passtherethrough so that pallet 10 can be easily moved via a conventionalpallet jack. Optionally, bottom board 16 can be formed form a singleboard or from a plurality of smaller boards. One or more tags 58 canoptionally be formed into or onto top plate 12. Tags 58 can comprisetext and/or graphics. For example, in one non-limiting embodiment, oneor more tags 58 can comprise a company logo and/or product descriptionor product number.

Optionally, as best illustrated in FIG. 17C, the end portion ofstringers 14 can be tapered slightly such that they are longer at thetop than at the bottom. Likewise, as best illustrated in FIG. 17C, topplate 12 can be slightly longer than bottom board 16. This taperedconfiguration can help reduce the possibility for the bottom edge of thepallet and or the bottom end of stringer 14 to snag on items, such asproduct stacked on immediately adjacent pallets or the top plates of theimmediately adjacent pallets. In one embodiment, nubs 54, top plate 12,stringers 14, and/or tags 58 can all be molded in a single mold at thesame time as a single continuous piece of material, as was alsodescribed in relation to FIG. 16. In this embodiment, one or more bottomboards, most preferably with openings 56 formed therein can then beattached to the bottom of stringers 14 via fasteners—preferably metalfasteners, and most preferably via metal screws. Of course, one or moreof nubs 54, top plate 12, stringers 16, and/or tags 58 can be formedindividually and subsequently attached together—for example using one ormore fasteners. For example, in one embodiment, nubs 54 can be attachedto top plate 12 via one or more fasteners. In one embodiment, as bestillustrated on FIG. 17B, the width of top plate 12 can be molded wide sothat it overhangs the outside stringers 14 and bottom board 16. As such,a user can provide one mold that forms a top plate that overhangs thebottom boards and stringers and the user can then trim one or both sidesof the overhanging portion to reduce the width of the pallet to adesirable width, thereby producing pallets of various sizes from asingle mold.

Note that in the specification and claims, “about” or “approximately”means within twenty percent (20%) of the numerical amount cited.

Although the invention has been described in detail with particularreference to these preferred embodiments, other embodiments can achievethe same results. Variations and modifications of the present inventionwill be obvious to those skilled in the art and it is intended to coverin the appended claims all such modifications and equivalents. Theentire disclosures of all references, applications, patents, andpublications cited above are hereby incorporated by reference.

What is claimed is:
 1. A plastic pallet comprising: a plastic top platecomprising a textured pattern formed on at least one side thereof; twoor more plastic stringers; at least one bottom board, said at least onebottom board comprising a textured pattern surface; and a firstplurality of fasteners securing said bottom boards to said stringers. 2.The plastic pallet of claim 1 further comprising a second plurality offasteners securing said plastic top plate to said two or more plasticstringers.
 3. The plastic pallet of claim 1 wherein said stringers areintegrally formed in said plastic top plate.
 4. The plastic pallet ofclaim 1 wherein said top plate comprises a plurality of corner piecesprojecting from a top thereof.
 5. The plastic pallet of claim 1 furthercomprising a first IBC attached thereto.
 6. The plastic pallet of claim5 wherein said top plate comprise a void formed at a location below anoutlet of the first IBC.
 7. The plastic pallet of claim 5 wherein saidbottom board comprises an opening that aligns with an inlet of a secondIBC when said plastic pallet is placed atop said second IBC.
 8. Theplastic pallet of claim 5 wherein said bottom board is sized to sitinside of a frame for a second IBC.
 9. The plastic pallet of claim 5wherein said stringers extend beyond said at least one bottom board byat least 1.5 inches on each end.
 10. The plastic pallet of claim 1further comprising one or more barrel retention spaces formed on saidtop plate, said barrel retention spaces defined at least partially byone or more corner pieces.
 11. The plastic pallet of claim 10 whereinsaid barrel retention spaces are further defined by one or more barrelspacers.
 12. The plastic pallet of claim 10 wherein said plastic palletcomprises four or more barrel retention spaces formed on said top plate.13. The plastic pallet of claim 1 wherein said two or more plasticstringers comprise a stiffener cutout.
 14. The plastic pallet of claim13 further comprising at least one stiffener extending from at least oneof said two or more stringers to at least one other of said two or morestringers.
 15. The plastic pallet of claim 1 wherein said firstplurality of fasteners comprises metal screws.
 16. A plastic palletcomprising: a plastic top plate comprising two or more integrally formedstringers; at least one bottom board; and a first plurality of metalscrews securing said bottom boards to said stringers.
 17. The plasticpallet of claim 16 further comprising an IBC attached to a top thereofand wherein said plastic top plate comprises a void formed at a locationbelow said IBC.
 18. A method for forming a plastic pallet comprising:attaching a plastic top plate to two or more plastic stringers; andattaching at least one bottom board to the two or more plastic stringerswith a plurality of metal fasteners.
 19. The method of claim 18 whereinattaching a plastic top plate to two or more plastic stringers comprisesintegrally forming the two or more plastic stringers into the plastictop plate.
 20. The method of claim 18 further comprising forming theplastic top plate from a compression mold and wherein the at least onebottom board is at least partially formed from the compression mold. 21.The method of claim 20 further comprising at least partially forming theat least one bottom board by cutting it to a desired size.